Food & Beverage Processing Solutions Using Information and Communications Technology to build smart factories and traceable products Computer-assisted manufacturing system to streamline the food & beverage manufacturing process and establish a track and trace system from logistics management to production control
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Intelligent Food & Beverage Manufacturing Overview ICT (Information and Communications Technology) realizes smart factories and synchronize sales and production In the new era of globalization, food and beverage producers operate manufacturing facilities located in different countries with a global supply chain. Therefore, building up a standardized and scalable production system is imperative for today’s corporate competitiveness. Smart factories are an industrial trend that use networking and intelligent technologies to integrate all the process, from sourcing and manufacturing to distribution.
Material Weighing & Mixing Operators scan the barcode, measure weight of materials, divide them into smaller parcels and put tags on the parcels.
Material Requisition Operators pick materials from the storeroom according to their production order, and read the barcode on the material parcels they pick.
Product Inspection Packages and labels are examined and quality of food/ beverage is tested.
Packaging & Labeling Products are packaged and labeled with information including expiration date.
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Filling & Sealing Food/beverage is packed into a container and sealed in an aseptic process.
Dosing & Mixing Ingredients are fed into mixing tanks for production.
Business Information Center Management Platform • Device networking • Real time remote monitoring and control • Data collection, analyses and graphic presentation • Interfacing and Integration of manufacturing processes
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Facts & Trends in the Food & Beverage Processing Industry The difficulty in realizing complete tracing records A complete food record tracing back to the very beginning of its ingredient supply, through manufacturing procedures, to logistics, transportation and finally to the retail site is de facto difficult. There are many links or interfaces of systems, many receipts and paperwork involved. A loophole or break could happen in any stage and affect data authenticity, making real time monitoring and preventive actions difficult.
The supply chain of food & beverage products
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New Ideas for the Food & Beverage Industry To fulfill complete and correct track and trace food records, smart technologies and new management tools are available. In the smart food factory, Patrol Inspection System is used in connection with the company’s Enterprise Resource Planning (ERP) system and Manufacturing Execution System (MES) to allow operators at each processing stage to report production status, equipment status, material usage and quality control. Operators usually use intelligent tools such as barcode readers or industrial tablets to enter data, and all devices in the factory are connected in a network. These are typical practices of a smart factory.
The collected production data will be compared against production plans and Standard Operating Procedures (SOP), and if any abnormality is detected, an alert or alarm will be issued to prompt actions. Production records are also used to produce Key Performance Indicators (KPI) assessment to assist in the company’s policy making.
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Intelligent Food & Beverage Processing Solution Intelligent food & beverage processing solution based upon advanced ICT technologies, which is a seamless combination of shop floor data collection--including weighing and mixing , patrol inspection and equipment integration-- and higher level MES modules including WIP control, SPC, equipment management, and alarm management, expected to fulfill the manufacturer’s Computer-Integrated Manufacturing (CIM) objectives.
Seven Major Function Modules Work In Process (WIP) Statistical Process Control (SPC)
Including sign in/out management, privilege settings, master file settings, system settings, analysis charts and tables
Alarm Management (ALM)
Including privilege settings, alarm management settings, alarm management jobs, query and reporting, system administration and network services
Equipment Management System (EMS)
Including master file settings, task scheduling settings, equipment repair and maintenance, equipment parts management and data query
Material Weighing & Mixing
Patrol Inspection
Equipment Integration
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Including basic information settings, production management, exception management, label management, carrier management, data query administration settings
Including material weight measurement, dosing and mixing jobs, and job records Overseeing the operations of sterilization, filling & packing, packaging, and quality assessment
Fetching digital data and integrating with SPC module into a quality management system; with ALM module into an alarm system; with EMS module into an equipment system
Work In Process (WIP) Module Work In Process (WIP) module is the core module of Manufacturing Execution Systems (MES), which provides diverse functions and intuitive interface to allow users to receive information such as production records, quality reports, material usage and an equipment status, so that the users can perform real time control and management tasks over the shop floor to prevent processing errors. Basic Information Settings • Provides equipment management, production/process control, alerts management, label management, system management, etc.
Production Management • Provides information of production orders and status of jobs; issues important production notes; setting time intervals for data display.
Equipment Management
• Designates cables, ports, processing modes and grouping of specific machines; defines status rules for “Run”, “Down”and “Idle”.
Carrier Management • Provides functions of carrier establishment, management, renaming, and search queries.
Exception Management • Changes of equipment and port status.
Data Query • Provides search queries for reports on work-in-process, materials, CIP info, production orders, operator working hours, etc.
Reporting Services
• Provides 6 standard forms for recording equipment efficiency, like : material usage, packaging, and equipment failure statistics , etc.
System Management
• Provides external data columns, institutional management, languages and cultures, naming variables and filtering rules.
Statistical Process Control (SPC) Module The Statistical Process Control (SPC) module traces and records information pertinent to quality issues in manufacturing process. It simplifies and digitalizes complicate data into easy-to-understand charts and tables through statistics and computing algorithm based on process quality control theory. The results will help authority to establish a mechanism to identify reasons and deal with quality fluctuations, allowing for continuous improvement.
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Alarm Management (ALM) Module Aims to meet shop floor management requirements, the alarm management system sets frequency for alarm issuing, message-forwarding vehicles and receivers to create an effective alarm system. The ALM module is an open platform able to integrate various information systems in the company and instantly forward alarm messages on equipment abnormalities to personnel in charge to allow for fastest handling and reduce loss.
Equipment Management System (EMS) Module Equipment Management System (EMS) is a preventive maintenance platform that integrates maintenance and repair jobs, spare parts management and alarm functions to allow users optimize their important asset/ equipment utilization and reduce loss resulted from unexpected equipment failure. • Preventive maintenance: The computer will automatically produce a recommended maintenance schedule for factory
equip ment, Engineers can discuss on the feasibility of this schedule and make adjustments if there is any difficulty in practice.
• Repairs: By logging in the system and filling necessary forms, the system will automatically generate a code number and submitted to the engineering department for handling.
• Components management: The system will based on repairs applications., to check the amount... of parts issued, issuing date and the recipients shall be clearly recorded during and after a repair job.
• Maintenance notices issuing: The system will automatically send e-mails of a scheduled maintenance order to people in charge.
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Material Weighing and Mixing Module The module helps to standardize and computerize the operations in material storeroom, weighing area, and dosing and mixing area. All inbound materials are labeled with 1D/2D barcodes to facilitate measurement. The picking, request for and issuing of materials are implemented according to ERP procedures. In the weighing area, operators acquire materials according to production orders and recipes; inventory shortage and overage should be adjusted regularly.
Patrol Inspection Module This module allowing operators to enter data with a handheld touch panel while they are patrolling around the shop floor. The entered data is then transmitted to server host via Wi-Fi wireless connection and is compare against standard samples stored in the database to determine if there is an abnormality. In this way, the traditional handwritten forms are replaced by digital files which can be used for further purposes.
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Equipment Integration Module The equipment can be integrated in a network by either using Advantech ’s monitoring control software WebAccess to connect with shop floor PLCs to acquire equipment data; or use ADAM or other data loggers to connect with modified devices to acquire analog data or use T50 networking hub to acquire digital data. This helps to realize real time consecutive monitoring control instead of the traditional scattering checkpoints. The data acquired automatically can be used to compare with manual records to determine if there is an abnormality. The connection of devices is shown below:
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Case Studies
MES for Food & Beverage Project Introduction
System Requirements
Taiwan’s biggest food and beverage manufacturer initiated a MES to establish more efficient and accountable tracking records for their products so that they can quickly identify problematic ingredients and responsible suppliers.
Five units of the Advantech industrial panel PWS770 with WebAccess 7.1 are deployed in the field to collect real time production data at major control points, including ingredient measurement and proportioning, sterilization, filling and packaging. Some devices and meters are installed with wireless modules and can transmit data immediately; however, some still need workers to input data on-site. With a portable panel workers can walk around and input data immediately. They can also conveniently use a barcode reader to scan batch numbers or simply click on the touch screen with fingers to input data. The company also uses networking and intelligent technologies to integrate all the links in production process; including WIP, SPC, ALM, EMS, etc. to realize smart factory from production to distribution.
Conclusion Before the deployment of the electronic MES system, production records were mostly done by paperwork, it took one or two days for the company to find related production data when problems occurred, and it was difficult for them to identify root causes as a great number of ingredients and suppliers are involved in mass and continual production. With the new system, all ingredients and their suppliers are encoded at the beginning and linked to a database, so that all production data can be traced throughout the process and problematic ingredients and suppliers can be immediately identified. Sometimes problems can even be prevented in process due to the alarm features of the system. The mobility provided by Advantech industrial panels helps to realize walk-around management and realtime monitoring. Meanwhile, WebAccess not only allows for instant data input and display but also provides statistical analyses and historical trends in very easy-to-read figures and tables to be reviewed by senior officers at company headquarters.
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Solution Package
Intelligent Data Entry and Equipment Integration Solution Food & Beverage Processing Solution focusing on equipment integration, material weighing and mixing, patrol inspection, WIP, SPC, ALM and EMS, which can be used to organize and build up six major systems for customers to choose to install according to their own needs. The six systems are divided into two groups based on their ways of data entry: “Intelligent Data Entry” and “Equipment Integration”. The former uses industrial touch panels to report shop floor information, and the later acquires real time production data via equipment integration enabled by Advantech products like WebAccess and ADAM. The acquired data will be further processed for applications. To realize complete and seamless Computer-Integrated Manufacturing (CIM).
Intelligent Data Entry
Equipment Integration
Material Weighing & Mixing System
Quality Control System
Material Weighing & Mixing Module
Equipment Integration Module • Digital data acquisition
• Weighing operation • Dosing & mixing operation
SPC Module
• Operation completion record
• Sign in/out management • Privilege settings • Charts and tables analyses
Patrol Inspection System Patrol Inspection Module
Alarm System
• Aseptic operation
Equipment Integration Module
• Filling/packing operation
• Digital data acquisition
• Quality assessment operation WIP Control Module
ALM Module
• Production control operation
• Privilege settings
• Exception management operation
• Alarm management operation
• Carrier management
Equipment System Intelligent System
Equipment Integration Module EMS Module
Material Weighing & Mixing Module
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• Task scheduling settings
Patrol Inspection Module
• Equipment maintenance and repairs
WIP Control Module
• Equipment parts management
Solution
Intelligent Data Entry
Equipment Integration
Total Soltuion • Material Weighing & Mixing Module
• Material Weighing & Mixing Module Function Module
• Patrol Inspection Module • WIP Control Module
• Equipment Integration Module
• Patrol Inspection Module
• SPC Module
• Equipment Integration Module
• ALM Module
• WIP Module
• EMS Module
• SPC Module • ALM Module • EMS Module
Intelligent HMI/SCADA software • 100% Browser-based • Easy to connect and control a variety of IoT devices
300 tags
300 tags
600 tags
• Supports all kinds of mobile devices and browsers CPU : Intel Atom N2600 or above / RAM : 2GB / HDD : SSD 32GB OS : Windows 7 Embedded Hand-held Panel Computer PWS-770
I/O ports : 2 x USB 2.0 / 1 x RS232 / 1 x VGA / 1 x Audio in / 1 x Audio out / 1 x DC-in WI-FI : 802.11b/g/n WLAN Build in, Bluetooth class 2.4.0 Built in Screen size : 10.4” Lithium battery: 1.1V 1900mAhr, 1 x embedded
ADAM-6060
Provides 6 input and 6 output channels Data Acquisition I/O
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ADAM-6050
Provides 12 input and 6 output channels ADAM-6017
Provides 8 analog input and 2 output channels
Server Equipment
Others
• Host server
• Host server
• Back-up server
• Back-up server
• Networking and cabling engineering
• Networking and cabling engineering • Equipment modification for networking (Bluetooth)
DB Server OS: Windows Server 2008 R2 Standard or above Recommended Software Specifications
Data Base: (either one) • SQL Server 2008 R2 Standard Edition or above • Oracle Database 11g Standard Edition or above AP Server OS: Windows Server 2008 R2 Standard or above
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Choose Advantech as Your Best Partner Founded more than thirty years ago, Advantech has become an intelligent service industry leader, and has offices around the world. Through close cooperation with a vertical field of systems integrators, Advantech provides a wider range of applications in each industry, and comprehensive smart city and Internet of Things (IoT) solutions in order to facilitate a convenient and smart life. Advantech’s mission is to continue to drive the earth to become more intelligent, to drive innovation of smart city, to build the model IoT industry, to assist industries to accelerate intelligence operations to become the most influential global businesses of smart city and Internet of Things (IoT).
Smart city solutions Advantech’s five major smart city solutions make the system able to fully utilize Internet of Things (IoT) architecture for comprehensive sensing, reliable communications, and intelligent processing. These solutions provide a more intelligent experience to the public, business, and government, improving the overall quality and image of a city.
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Why Advantech Designing specific solutions according to industry characteristics
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In order to offer the market new value-added services, and to meet the needs of as it moves from “product” to “services”, Advantech provides innovative SRPs (Solution Ready Packages) for various professional industries. Advantech also provides application solutions for industry-specific hardware and more intelligent services to its customers, allowing customers to focus on their work, and make application integration easier.
Perfect cloud integration solutions Advantech has been cultivating various industries for many years, understanding the purposes and needs of users, and providing appropriate hardware and software to match solutions. With particular emphasis on the product development of cloud-based architecture in recent years, WebAccess+, a new industrial cloud software, provides comprehensive evolution of intelligent remote detection management service that instantly detects and accurately grasps the system state.
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After Service
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Product Warranty
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With a total training solution which including multimedia player software with user demonstrations and hands-on experience system maintenance staff can learn to operate their system in no time.
Intelligent Agricultural and Environmental Protection
Alliance
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Customer-oriented Support
Advantech is a global embedded computing researcher, developer, and manufacturer, providing various industries a variety of industrial PCs, touch screen, data acquisition modules, and other products. With stable quality assurance, Advantech products can not only be used in inside, but also outside in harsh environments. With the support of Advantech industrial computers, Advantech provides intelligent and stable project planning to industries.
Advantech ’s complete technical and repair support provides a variety of customizable after-sales services, including extended warranty, advance replacement, upgrade, fast repair and so on. With hotline AE 24/7 technical support, we keep you investment at peak performance and within your budget.
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Smart HMI/SCADA Software
Intelligent Video Software
Interative Multimedia Software
Network Management Software
- 100% browser-based HMI/SCADA software
- Intelligent Video Platform
- Digital Signage Management Platform
- Network Equipment Management and Monitor
- Easy to connect and control a variety of IoT Devices
- Intelligent Video Analytics Modules
- Intelligent Programming Platform
- Integration of Network Topology
- Supports a variety of mobile devices and browsers
- Modulized SDK ready for software integration
- Supports Industries and Application Scenarios
- Location Identification for Wide Area Deployment
Advantech invites system integrator partners to join the WebAccess+ Alliance to jointly develop the Internet of Things (IoT) and create business opportunities
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